SOUTH DAKOTA SCHOOL OF MINES AND …webpages.sdsmt.edu/~djensen/IENG 464-465/Materials/ME 2011...

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SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

SENIOR DESIGN PROJECT PROPOSAL LIST – FALL 2011

New Project

Project # 1 - ASME Human Powered Vehicle 2012 (ME, IENG, MetE)

Project # 2 - Baja SAE 2012 (ME, IENG, MetE)

Project # 3 - Formula SAE 2012 (ME, IENG, EE, MetE)

Project # 4 - SAE Aero Design 2012 (ME, IENG, MetE)

Project # 5 - SAE Zero Emissions Snowmobile 2012 (ME, EE, IENG, MetE)

Project # 6 - UAV 2012 (ME, EE, CENG, CSC, MetE)

Project # 7 - SAE Supermileage 2012 (ME, EE, IENG, MetE)

Project # 8 - WDTI Partnership in AMD World Championship (ME, MetE, IENG)

Project # 9 - Composite Acoustic Guitar (ME, IENG, MetE)

Project # 10 - ASME SDC – Energy Relay (ME, EE/CENG, ChemE)

Project # 11 - Moonrockers: NASA Lunar Regolith Excavator (ME, EE, CENG, CSC)

Project # 12 - Development of Autonomous Submersible to Explore Extreme Environments

(ME, Chem/ChemE, CENG, EE, IENG)

Project # 13 - Satellite Attitude Dynamics Simulator (ME, CENG, EE)

Project # 14 - Multifunctional Helmet (ME, MetE)

Project # 15 - State of the Art Directional Wave Tank with Wave Makers (ME, EE, CENG, CE)

Project # 16 - Floating Hydro Electric in the Amazon (CE, EE, IENG, ME)

Project # 17 - purePack 2.0 – Portable Water Purification System (ME, EE, IENG, EnvE)

Project # 18 - Robotic Friction Stir Welding of Aluminum Weldments using Linear and Circular

Paths (ME, EE, CENG, MetE, CSC)

Project # 19 - Airflow Enthalpy Monitor (EE, CENG, ME)

Project # 20 - Rehabilitation Device (ME, CENG, EE, IENG)

Project # 21 - ABS Brake Concept Trike (ME, EE, CENG)

Project # 22 - Multi-Axis Robotic CNC MIG Welder (ME, CSC)

Project # 23 - Radiation Hardened Robot (CENG, CSC, EE, ME)

Project # 24 - Bite Force Estimator (ME, MetE)

Project # 25 - Cold Spray Technology (ME, MetE)

Project # 26 - 4-Wheel Tilt Vehicle (ME): This project is tentative

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SENIOR DESIGN PROJECT PROPOSAL

Project Title: ASME Human Powered Vehicle 2012

Proposed/Advised by: Dr. Matejcik, Dr. Ellingson, Kim Osberg, Dr. Dolan, HPV team

Sponsored by: CAMP, SA, ASME

Project Description (including objectives and requirements):

A vehicle will be designed, built, and tested for the ASME Human Powered Vehicle Competition.

Information can be found at: http://www.asme.org/Events/Contests/

Project Duration: 2 semesters

Technical Areas Encompassed (e.g., machine design, controls):

machine design, manufacturing, materials, composites, ergonomics, aerodynamics

Any other special requirements:

Senior design members are expected to attend the competition.

Number of Students/Disciplines required (e.g., 2 ME, 1 EE, 1 CS):

3 ME, 2IE, and 1 MetE would be desired

http://www.asme.org/Events/Contests/

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Project Title: Baja SAE 2012

Proposed/Advised by: Dr. Dolan, Dr. Muci, Kim Osberg, Baja SAE Team

Sponsored by: CAMP, SAE, SA

Project Description:

Baja SAE consists of competitions that simulate real-world engineering design projects and their related

challenges. Engineering students are tasked to design and build an off-road vehicle that will survive the

severe punishment of rough terrain and in the East competition—water.

The object of the competition is to provide SAE student members with a challenging project that

involves the planning and manufacturing tasks found when introducing a new product to the consumer

industrial market. Teams compete against one another to have their design accepted for manufacture by a

fictitious firm. Students must function as a team to not only design, build, test, promote, and race a

vehicle within the limits of the rules, but also to generate financial support for their project and manage

their educational priorities.

All vehicles are powered by a ten-horsepower Intek Model 20 engine donated by Briggs & Stratton

Corporation. For over twenty-five years, the generosity of Briggs & Stratton has enabled SAE to provide

each team with a dependable engine free of charge. Use of the same engine by all the teams creates a

more challenging engineering design test.

Project Duration:

2 semesters


Dynamics, vehicle dynamics, machine and structural design, human factors, manufacturing


The students must be SAE members to attend the competition. All seniors are expected to attend the

competition.


A team consisting of 6 MEs, 2IEs, and 1 Met student would be desired, with an emphasis for one team

member taking ME 428: Finite Element Analysis to focus on frame analysis.

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Project Title: Formula SAE 2012

Proposed/Advised by: Dr. Dolan, Dr. Ellingson, Kim Osberg, Chuck Schilling, FSAE Team

Sponsored by: CAMP, SA, SAE, Poet, Ford

Project Description: The Formula SAE competition is for SAE student members to conceive, design,

fabricate, and compete with small formula-style racing cars. The restrictions on the car frame and engine

are limited so that the knowledge, creativity, and imagination of the students are challenged. For the

purpose of this competition, the students are to assume that a manufacturing firm has engaged them to

produce a prototype car for evaluation as a production item. The intended sales market is the

nonprofessional weekend autocross racer. Therefore, the car must have very high performance in terms

of its acceleration, braking, and handling qualities. The car must be low in cost, easy to maintain, and

reliable. In addition, the car's marketability is enhanced by other factors such as aesthetics, comfort and

use of common parts.

The cars are judged in a series of static and dynamic events including: technical inspection, cost,

presentation, and engineering design, solo performance trials, and high performance track endurance.

These events are scored to determine how well the car performs. In each event, the manufacturing firm

has specified minimum acceptable performance levels that are reflected in the scoring equations.

Further information can be obtained at: http://students.sae.org/competitions/formulaseries/



Dynamics, fluids, aerodynamics, machine and structural design, electric circuits, measurements and

instrumentation, human factors, manufacturing, composites, engines


The students must be SAE members to attend the competition. All seniors are expected to attend the

competition.


A team of 6 MEs, 2 IEs, 2 EEs and 2 Met students would be desired.

http://students.sae.org/competitions/formulaseries/

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Project Title: SAE Aero Design 2012

Proposed/Advised by: Dr. Dolan, Kim Osberg

Sponsored by: CAMP, SA, SAE, SAE Aero Design Team


The Aero Design® Competition challenges engineering students to conceive, design, fabricate, and test a

radio controlled aircraft that can take off and land while carrying the maximum cargo.

Competition information is posted at: http://students.sae.org/competitions/aerodesign/



Dynamics, machine and structural design, instrumentation and testing, controls, fluids, aerodynamics,

manufacturing


The students must be SAE members to attend the competition, and seniors are expected to attend.


A team of 4 MEs, 2 IEs and 2 Met students would be desired.

http://students.sae.org/competitions/aerodesign/

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Project Title: SAE Zero Emissions Snowmobile 2012

Proposed/Advised by: Dr. Batchelder, Dr. Dolan, Kim Osberg, and the AFV Team

Sponsored by: CAMP, SAE


The object of the competition is to provide SAE student members with a challenging project that

involves the planning and manufacturing tasks found when introducing a new product to the consumer

industrial market. Teams compete against one another to have their design accepted for manufacture by a

fictitious firm. Students must function as a team to not only design, build, test, promote, and demonstrate

a zero-emissions snowmobile within the limits of the rules, but also to generate financial support for

their project and manage their educational priorities.

The SDSM&T team will use an electric motor powered by batteries.

Rules are at: http://students.sae.org/competitions/snow/

Project Duration:

2 semesters


Electric power, motors, controls, dynamics, vehicle dynamics, machine and structural design, human

factors, manufacturing


The students must be SAE members to attend the competition. Senior design members are expected to

attend the competition.


A team consisting of 4 MEs, 4EEs, 2IEs, and 1 Met would be desired.

http://students.sae.org/competitions/snow/

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Project Title: UAV 2012

Proposed/Advised by: Profs. McGough, Dolan, Batchelder, Weiss, Linde, Hoover, Tolle;

Kim Osberg

External advisors: Jason Howe, Mark Sauder

Grad students: Jaiyi Liu, Jordan Ritz, and UAV team

Sponsored by: CAMP, SA


This senior design team will work to configure the Unmanned Aerial Vehicle (UAV) Team‘s vertical-

take-off-and-landing (VTOL) sub-vehicle for the interior search mission of 2012. Work will be done on

the control system to provide the jump-drive drop and pick-up system.

This Senior Design Team will coordinate all efforts with the Chief Engineer and Team Manager of the

UAV Team as well as the team at large. All final design decisions will be the collaborative efforts of the

UAV Team leadership, the UAV Team, and the Senior Design Team members. Additionally, it is

desired that Senior Design Team members become and remain SDSM&T UAV Team members in good

standing.

Competition rules and highlights are at:

http://iarc.angel-strike.com/

Project Duration: 1 year


Controls, machine design, composite materials and structures, fluid mechanics, instrumentation and testing,

software engineering, programming


Students would be members of the UAV competition team. Senior design members are expected to attend

the competition.


2 ME, 1 EE, 2 CompE, 3 CSC, 1 MET would be desired

http://avdil.gtri.gatech.edu/AUVS/IARCLaunchPoint.html

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Project Title: SAE Supermileage 2012

Proposed/Advised by: Dr. Abata, Dr. Dolan, CAMP

Sponsored by: Nucor Steel and CAMP

Project Description: The Supermileage® competition provides engineering and technology students

with a challenging design project that involves the development and construction of a single-person,

fuel-efficient vehicle. Vehicles are powered by a small four-cycle engine. The vehicles will run a

specified course with the vehicle obtaining the highest combined kilometers per liter (miles per gallon)

rating plus design segment points winning the event. Students have the opportunity to set a world

fuel economy record and increase public awareness of fuel economy. Engines are donated by Briggs

& Stratton.

Further information can be obtained at: http://students.sae.org/competitions/supermileage/



Dynamics, fluids, aerodynamics, machine and structural design, measurements and instrumentation,

engines, human factors, manufacturing, composites.


The students must be SAE members to attend the competition. All seniors on the project would be

expected to attend the competition.


A team of 4 MEs, 2 EEs, 1 IE, and 1 Met student would be desired.

http://students.sae.org/competitions/formulaseries/

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Project Title: WDTI Partnership in AMD World Championship

Proposed/Advised by: Dan Dolan, Mike West, Jason Ash, Luke Steinmetz (WDTI), and Mike

Prugh

Sponsored by: Prugh Design and Black Hills Harley Davidson


In 2009-2010, Western Dakota Technical Institute partnered with Prugh Design and the Black Hills

Harley Davidson to develop a custom modified Harley for the 2010 American Motorcycle Dealer

(AMD) World Championship of Custom Bike Building that takes place each year during the Sturgis

Rally and features custom motorcycles from around the world. Prugh Design and Black Hills Harley

Davidson are looking to partner again with a collaborative effort between WDTI and the students at

SDSM&T. The scope of the project focuses on the form as well as the function in the mechanical design

of a custom bike and will require in-house parts to be designed and manufactured. Details on the 2010

competition bike can be found at the following:

http://www.amdchampionship.com/bikes/2509-prugh-design-black-hills-harley-davidson-filter.html



ME: Machine design, vehicle dynamics, product development

MetE: Material selection, product development

IENG: Project management, ergonomics, product development



4 ME, 2 MetE, and 1 IENG would be desired

http://www.amdchampionship.com/bikes/2509-prugh-design-black-hills-harley-davidson-filter.html

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Project Title: Composite Acoustic Guitar

Proposed/Advised by: Dr. Dolan

Sponsored by: CAMP, Gary Santa, Dr. Dolan


A composite (carbon fiber) acoustic 6-string guitar will be designed, built, and tested. It is desired to focus

on the manufacturing technology while assuring a professional sounding guitar. The guitar should have

roughly the shape, size, and sound of a dreadnought guitar.



machine design, structures, manufacturing, materials, composites, ergonomics, acoustics, vibrations, music


It would be helpful if at least one of the team members were a guitar player.


3 ME, 1 IE, and 1 MetE would be desired

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SENIOR DESIGN PROJECT PROPOSAL Project Title: ASME STUDENT DESIGN CONTEST – Energy Relay

Proposed/Advised by: Mr. Jason Ash and Dr. Michael Batchelder

Sponsored by:

A $500 budget is available from the ASME student chapter with the possibility of an additional $500 depending on

project needs/resources. Travel and hotel expenses will be covered by your ASME student section.


Providing energy to a world with a growing population and rising expectations is a challenge that engineers must

embrace and solve. So many factors must be considered and balanced: cost, efficiency, resource availability,

environmental impact, sustainability, and more. Many different potential solutions are being proposed and

developed. While the winners have yet to be determined, it is safe to assume that the future will include a wide

variety of solutions that together will power our planet.

The goal of the 2012 ASME Student Design Competition is to design four self-propelled devices which can

collectively complete a relay race in the shortest period of time. Each device must contain an on-board energy

source and trigger the motion on the next device. Bonuses will be awarded for devices having different energy

sources and for initiating subsequent devices.

http://files.asme.org/asmeorg/Events/Contests/DesignContest/28571.pdf



Machine design, mechatronics, controls, programming, and chemical engineering


ASME membership required for 2011-2012 at the $25 student rate.

Competition Prizes:

Number of Students/Disciplines required

Up to 4 ME/EE/CENG/ChemE students (Team cannot exceed 4 students): The ideal team would be 1 of

each discipline or 2 ME, 1 EE or CENG, and 1 ChemE

http://files.asme.org/asmeorg/Events/Contests/DesignContest/28571.pdf

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SENIOR DESIGN PROJECT PROPOSAL Project Title: NASA Lunabotics: Lunar Regolith Excavator

Proposed/Advised by: Mr. Jason Ash and Dr.‘s Michael Batchelder, Jeff McGough, and Charles Tolle along with

graduate advisor Mr. Ryan Housh

Sponsored by:

A $5000 baseline funding request has been sent to NASA with positive response for support from the South Dakota

Space Grant Consortium. Additional fundraising may be required.


The Lunabotics Mining Competition is a university-level competition designed to engage and retain students in

science, technology, engineering and mathematics (STEM). NASA will directly benefit from the competition by

encouraging the development of innovative lunar excavation concepts from universities which may result in clever

ideas and solutions which could be applied to an actual lunar excavation device or payload. The challenge is for

students to design and build a remote controlled or autonomous excavator, called a lunabot, that can collect and

deposit a minimum of 10 kilograms of lunar simulant within 15 minutes. The complexities of the challenge include

the abrasive characteristics of the lunar simulant, the weight and size limitations of the lunabot, and the ability to

control the lunabot from a remote control center. This will be the 3rd year of the competition with the first place

team last year delivering 237.4 kg. Complete details of the competition are provided at the following location:

http://www.nasa.gov/lunabotics



Machine design, mechatronics, controls, vision systems, and programming


K-12 Outreach required as part of this project.

Competition will be at Kennedy Space Center from May 21-26, 2012.

Competition Prizes:

$5000, $2500, and $1000 for 1st, 2

nd, and 3

rd place along with VIP Kennedy Space Center launch tickets

Additional prizes for individual and overall competition categories.


5-7 ME/EE/CENG/CSC students (Ideal would be 2-3 ME, 2 EE/CENG, 1-2 CSC)

http://www.nasa.gov/lunabotics

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Project Title: Development of Autonomous Submersible to Explore Extreme Environments

Proposed/Advised by: Drs. Tolle, McGough, Matejcik, and Mr. Ash

Sponsored by: South Dakota Space Grant NASA ($8k is in place to support implementation)


The AUV (Autonomous Underwater Vehicle) team is looking for senior design students from a variety of

disciplines. The team is tasked with the design and development of a submersible capable of autonomously

navigating in confined spaces at pressures of up to 1500 psi for three hours and then returning to its departure point.

This vehicle is intended for use in the Sanford Lab (aka what is to be DUSEL some day) but is being designed for a

variety of applications including open water exploration with Yellowstone lake, deep ocean exploration, and

possible missions to Europa (http://en.wikipedia.org/wiki/Europa_(moon)). This will be the 3rd

year for the team.

In pervious years the team has created and fabricated two frame designs, two different thruster systems, a

transmit/receiver sonar sounder, battery module controller and a designed for the power distribution system. There

are numerous additional needs yet to be accomplished before basic navigation and operation can begin, some

additional projects are listed below:

• A buoyancy system needs to be developed

• A supervisory power system needs to be designed and implemented – utilizing the existing battery module

controller subsystem

• A battery module enclosure subsystem needs to be designed and implemented

• A force transducer feedback system for thruster control must be designed and manufactured

• Low level thruster control systems must be developed and implemented

• An attitude control system must be developed and implemented

• Sensory systems must be developed and implemented, i.e. the sonar sounder needs to complete testing and

integrated to form a full sonar sub-system, a new UV/IR/visual camera system needs to be designed

• A high pressure water and gas sampling system needs to be designed and implemented

• A transportation and deployment system must be designed and manufactured

• Mission planning, guidance, and navigation algorithms must be designed and put in place

• A GUI interface systems for planning system missions needs to be developed

*Note, not all items listed above needed to be solved during this year’s efforts – the actual

team will focus on items that lien towards their knowledge, interest and talents.



machine design, mechatronics, electronics, and controls

Number of Students/Disciplines required:

This year 1-2 CENG, 1-2 Chem/ChemE, 4-6 EE, 2 IENG, and 4-6 ME are desired – all are welcome.

For more information stop by our lab in EP-335 and contact Dr. Charles Tolle, e-mail: [email protected] or

Andrew Muxen, e-mail: [email protected]

mailto:[email protected]

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Project Title: Satellite Attitude Dynamics Simulator

Proposed/Advised by: Drs. Tolle, Bedillion + others potentially

Sponsored by: South Dakota NASA Space Grant / AUV Team

($5K is in place to support implementation)


This project is an offshoot of the South Dakota NASA Space Grant AUV team. If we are to travel to

Europa (http://en.wikipedia.org/wiki/Europa_(moon)) our submersible spacecraft rover will need a

communication link back to earth. This project is to design and build a small satellite simulator so that

future students can work on satellite controllers, star pointing algorithms, communication links, etc.

Several such simulators can be seen in Agrawal and Rasmussen paper entitled: ―Air Bearing Based

Satellite Attitude Dynamics Simulator for Control Software Research and Development‖ available at

http://faculty.nps.edu/agrawal/docs/spie-agrawal-rasmussen.pdf. The main goal in this year‘s effort is to

fabricate an air bearing, design a mounting table (similar to a tooling table), design a thruster system and

implement low level thruster electronics.



machine design, mechatronics, and controls


This year 2 ME, 1 CENG, 1 EE are desired, additional students are welcome.

For more information Contact Dr. Charles Tolle, e-mail: [email protected] or visit our lab in EP-

335.

http://en.wikipedia.org/wiki/Europa_(moon

http://faculty.nps.edu/agrawal/docs/spie-agrawal-rasmussen.pdf

mailto:[email protected]

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Project Title: Multifunctional Helmet

Proposed/Advised by: Dr. Karim Muci, Mr. Brandon Hinz, and Mr. Andrew Brady

Sponsored by:

This senior design project will be part of a research project sponsored by the US ARMY Research

Laboratory (ARL) that involves a close collaboration between the SDSM&T Computational Mechanics

Laboratory (CML) and the SDSM&T Composites and Polymer Engineering (CAPE) Laboratory.


The purpose of this project is to develop a multifunctional helmet for first responders that has a reasonable

cost and can provide adequate protection to the head in a wide variety of scenarios. The following example

illustrates the need for such a helmet. Currently Search and Rescue (SAR) teams across the nation

commonly use different helmets for the different services that they provide like vertical rescue, swiftwater

rescue, vehicle extrication, and building shoring among others. Besides the inherent costs and logistic

problems of having to deal with several different helmets, few if any of them are designed with

multifunctional capability for situations encountered beyond the mission profile.

Arrangements will be made so that the members of the senior design team have the opportunity to interact

with first responders in the Pennington County area to determine the needs that they have for the product

under consideration.

Project Duration: September 2011 – May 2012

Technical Areas Encompassed:

Product development, manufacturing, solid mechanics, fluid mechanics, and dynamics. The work will

include performing computer simulations, manufacturing of prototypes, and experimental testing.


US Citizenship is required to participate in this project.


2–3 Mechanical Engineering students.

Optional: 1 Metallurgical Engineering student.

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Project Title: State of the art directional wave tank with wave makers

Proposed/Advised by: U.A. Korde, M.A. Langerman, C.F. Schilling

Sponsored by: ME Department


Water waves concentrate the sun‘s energy by two orders of magnitude, can travel long distances and last

a long time. Waves have been seen as a source of ‗clean‘ energy for many decades in the worlds of

commercial and academic research and development. Energy conversion from waves usually requires

some form of dynamic mechanical interaction with the waves. This is often achieved by means of a

floating or submerged body oscillating in response to the waves and driving a linear or rotary electric or

hydraulic generator via a suitable power transfer mechanism.

Successful implementation of any such energy conversion scheme depends on rigorous analysis and

model testing. To that end, this project proposes the construction of a wave tank capable of reproducing

at model scale the large variety of wave amplitude and directional spectra encountered in large bodies of

water (such as the Great Lakes or the oceans). The tank will include three essential components: (1) a

tank of dimensions to be specified at project start, (2) wave makers, and (3) wave absorbers (to prevent

multiple reflections from walls). A movable platform allowing access to models being tested and also

providing a place for instruments and model support struts would also be highly desirable. Part (2) will

include mechanical design and construction of the wave makers, design and construction of the drive

electronics, wave maker control system hardware and software (e.g. through Matlab or LabView).



Fluid mechanics, solid mechanics, dynamics, vibrations, controls, circuits, mechatronics, machine tool

operation, etc.

Any other special requirements: None.


5/6; MEs, EEs, CENGs, CEs all welcome.

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Project Title: Floating Hydro Electric in the Amazon

Proposed/Advised by: Tom Fontaine, Casey D. Heinrich, Michael S. Heinrich, Aaron Costello,

Rebekah Dargatz, and Jason Ash (tentative)

Sponsored by: World Micro Power

A $2,500 base budget has been provided by World Micro Power in addition to the 6 Kilowatt generator

head. World Micro Power is a non-profit organization administered by an all volunteer group of engineers

and technical specialists whose goal it is to use renewable resources to power remote villages in the

Amazon jungle. Specifically, to create durable, light weight, low maintenance ―zero head‖ hydro-electric

power at an affordable cost.


World Micro Power has a basic design for a zero head hydro-electric generator that is compatible with the

very harsh conditions of the Amazon River. It is hoped that he completed design will light all 100

dwellings at night and power a water filtration system during the day. The design requires fresh ideas and

many engineering and technical enhancements.

Designing a zero head generator for the remote Amazon jungle is an extremely challenging task. The

village of Santa Maria de Fatima is a remote village on the Amazon River outside Iquitos, Peru and is

accessible only by boat. The village has no source of light after dark and no way to power a water filtration

system.

The project would take the base design and improve it for: 1. Durability 2. Maintainability/Simplicity 3.

Efficiency 4. Minimum shipping weight 5. Compactness of disassembled components. 6. Low cost

The completed device will be required to pass a 24 hour duration test without failure.

Project Duration: 2 Semesters


Machine Design, Mechatronics, Controls, Fluids, Circuit Design, Hydro, and Programming.


The device will be installed in the Santa Maria del Fatima, Peru in the Summer of 2012.


8 ME/EE/CE/IENG

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Project Title: purePack 2.0 – Portable Water Purification System

Proposed/Advised by: Mr. Lucas Haan and Jason Ash (tentative)

Sponsored by: Labrusca Scientia, LLC

Project Background:

Last year (Spring 2010 – Fall 2011) a group of interdisciplinary senior design students at SDSM&T

worked to develop a prototype of a portable water purification system that produces clean, drinkable

water for contaminated fresh water locations and is powered by renewable energy. The group of students

then traveled to Chile to test and implement the prototype at an orphanage construction site in the Andes

Mountains where the prototype is currently in use. Due to the success of the project, these students have

now created a limited liability company (Labrusca Scientia, LLC) to develop even better portable water

purification system technologies. Labrusca Scientia, LLC aims to work with senior design students at

SDSM&T to help with the design of this development.


Labruscsa Scientia, LLC is developing a portable water purification system that produces clean, drinkable

water for contaminated fresh water locations and is powered by renewable energy. The entire system is

being revisited to optimize the product for movement into production. The main objectives of this project

are detailed below:

Objective 1: Design and develop a lightweight containment for entire system that is ergonomic and

fits the carry-on size constraints of airline travel

Objective 2: Optimize the pump/filtration system

Objective 3: Optimize the power storage and generation

Objective 4: Integrate more sensors and improve user interface system

Project Duration: 2 semesters (Fall 2011 – Spring 2012)


ME: structural integrity design, manufacturing, materials, ergonomics, fluid dynamics,

EE: alternative power generation, storage, and sensing (electrical circuit design)

IENG: ergonomics


Previous experience in travel abroad or an interest in such is recommended but not necessary


2 ME, 2 EE, 2 IENG, 1 ENVE

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Project Title: Robotic Friction Stir Welding of Aluminum Weldments using Linear and

Circular Paths

Proposed/Advised by: Chris Thompson, Johnathan Borrego, & Joshua Merry - Space Exploration

Technologies, Dr. Kalanovic, Dr. Widener (tentative)

Sponsored by: Space Exploration Technologies – Hawthorne, CA


Chris Thompson is the Vice President of Production Development at Space Exploration Technologies

(SpaceX). SpaceX has a desire to enter into robotic friction stir welding on their Falcon family of launch

vehicles and Dragon capsule that is used to transport equipment to and from the International Space

Station. The goal of this project is to develop a robotic friction stir welder using a common industrial

robot like those offered from ABB or FANUC. The robotic friction stir welder needs to perform and

control weld operations in 6061-T6 aluminum with material thicknesses ranging from 0.0625‖ up to

0.500‖. The proposed system must be all electric – no hydraulics. The end goals of this project are –

design and simulation of the proposed system, and demonstration of simple lap and square butt welds in

linear and circular motions time permitting.



Machine Design, Friction Stir Welding, Robotic Programming and Control, System Engineering


None that I am aware of at the moment


4-6 ME, EE, CENG, CSC

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Project Title: Airflow Enthalpy Monitor

Proposed/Advised by: Lance Weaver/Bernt Askildsen

Sponsored by: Lloyds Systems LLC


Develop an Enthalpy sensor that will also display wet bulb and dry bulb temperatures of airflow on a

LCD screen. The design will be focused around a low power microcontroller to ensure that a miniature

windmill will power the sensor system. The measured signals will also be transmitted to a wall box that

is connected to 120VAC. A successful outcome of project will be rewarded by stipends.

Project Duration:

2 semesters


Airflow dynamics, measurements, instrumentation, testing, software engineering, programming, wireless

communcations, SolidWorks, mechanical design of housings.


No


A team consisting of 1 EE, 1 CENG and 1 ME student is desired

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Project Title: Rehabilitation Device

Proposed/Advised by: Ryan Swenson, Doctor of Chiropractic, Jason Ash (tentative)

Sponsored by: Ryan Swenson, Doctor of Chiropractic


Ryan Swenson is a Chiropractic Doctor here at Black Hills Chiropractic. He has identified a need for a

rehabilitation therapy device whose goal is to strengthen and retrain neck muscles for patients suffering

from neck pain. Ryan would like to collaborate with SDSM&T and senior design students in the

development of a prototype that could be used in pursuing a patent. The students would be recognized

along with Ryan as the creators of the device, while Ryan would retain ownership of the patent.



Machine design, mechatronics, controls, human-factors, ergonomics, electrical circuit design


Signing a non-disclosure statement would be required for this project to maintain confidentiality


Ideally 4-6 EE, CENG, IENG, ME students (3 students minimum are needed and would not have to be

multidisciplinary)

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Project Title: ABS Brake Concept Trike

Proposed/Advised by: Gary Hamilton, Lehman Trikes Advisor, Dr. Bedillion

Sponsored by: Lehman Trikes


Add an ABS brake system to a 3-wheeled motorcycle for purposes of testing feasibility. The objective is to

produce a mule or first prototype to explore the possibility of adding ABS brakes to Lehman‘s product line.

The goal is to add to the basic engineering knowledge base at Lehman Trikes. This is a first stage design

for use in house and not intended as a final product for sale.



machine design, oil hydraulics, electronic controls


System would be designed as a test or demonstration on a Lehman model Trike. Lehman would provide a

trike, funding for purchase of parts ($2000) as well as welding and machining time (40 hours) at Lehman‘s

shop. Lehman would provide qualified engineers and operators to plan and conduct all dynamic testing.

Tests would be conducted on a closed track. Lehman accepts liability for testing conducted by Lehman

personnel. A more detailed agreement final must be written before this project starts.


3-5 ME, EE, CENG

23



Project Title: Multi-Axis Robotic CNC MIG Welder

Proposed/Advised by: Steven Franker

Sponsored by: Steven Franker & Team along with Fundraising


This project would entail designing and building a multi-axis robotic arm with low load actuators for CNC

MIG welding. The goal is to produce a practical device that could be easily used in small welding and

machine shops for repetitive welding tasks. No lengthy programming or computer skills required. Perfect

for consistently welding parts that can be mounted in a fixture or jig. It is also our goal to pursue the

marketability and possible patents of this project if it is successful. According to our research this would be

a unique product that no other company currently offers.



machine design, oil hydraulics, electronic controls



4-6 ME, CSC

24



Project Title: Radiation Hardened Robot

Proposed/Advised by: Los Alamos National Lab, National Security Technologies (contractor),

Texas Instruments, Drs. Bedillion, McGough, and Tolle

Sponsored by: Los Alamos National Lab


LANL would like a radiation hardened robot to drive down the beam line in an accelerator during

operation, perform diagnostics, and send back video.



ME: Robotics, machine design, controls

EE/CENG: Electrical circuits, controls

CSC: Programming, GUI Interface



4-6 ME, EE, CENG, CSC

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Project Title: Bite Force Estimator

Proposed/Advised by: Don Esker (Mammoth Site)/Dr. Marius Ellingsen

Sponsored by: Mammoth Site/AMP (MTS measurement time)


Since its discovery in 1986, the presence of the giant short-faced bear (Arctodus simus) in the Hot Springs

sinkhole has been attributed to the great ursid preying or scavenging on trapped mammoths. Despite this,

only one bone has ever been found with any bite marks or feeding traces: the rib 93HS031. This rib bears

two round depressions, interpreted as puncture marks from the canines of a large carnivoran. Determining

which carnivoran has been tricky, however. While the distance between the marks is consistent with inter-

canine spacing of an A. simus, they could also indicate a Panthera atrox (American lion), depending on

whether the canines were maxillary or mandibular.

We would like to design and test a mechanical apparatus that could answer the question once and for all.

In 2010, Gignac et al built a device to determine the bite force of an extinct animal. It operated by using a

hydraulic loading frame to press a hardened steel replica of the tooth into a cow bone, while a 25 kN load

cell measured the force applied. The force required to press the tooth into the cow bone to the same depth

as seen in the fossil gave an approximate bite force for the animal when alive. We‘d like to do essentially

the same here, and determine how much force was needed to puncture our rib. From there we‘ll compare

that force with published data on bite force estimates and our own finite element analysis to determine who

was chewing on mammoth bones in the sinkhole 26,000 years ago.



Machine design, solid mechanics, mechatronics, and measurements



3 or more ME/MET students

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SENIOR DESIGN PROJECT PROPOSAL Project Title: Cold Spray Technology

Proposed/Advised by: Christian Widener

Sponsored by: AMP


This is a tentative project through discussions with Christian Widener. He is interested in having students increase

the pressure capabilities of the current cold spray system. There are also additional design related items (nozzle

design, portability, etc.) with the current system that should be sufficient for a senior design project.



Machine design, solid mechanics, mechatronics, controls, measurements, and fluid mechanics



3 or more ME/MET students

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Project Title: 4-Wheel Tilt Vehicle

Proposed/Advised by: Dr. Dolan

Sponsored by: David Dieziger


Provide drawings and specifications for the construction of a vehicle based on US Patent 7,722,063 B2. Vehicle

will have 4 wheels, tilt and steer like a traditional motorcycle, be all-wheel drive, and have 250 to 400

horsepower.

The suspension system divides the vehicle into leaning and non-leaning components. The passenger

compartment and wheels lean together like a traditional motorcycle, and the rest of the vehicle (the drive train

and suspension system) remains upright like a standard automobile. It allows for a smoother ride than a

motorcycle because the suspension system, unlike a traditional motorcycle, does not experience any lateral or

turning acceleration. It allows for a smoother ride than a traditional automobile because it does not require

torsion bars, that negatively affect ride quality, to prevent body roll and weight transfer to the outside tires.

The most important feature of the design is that it solves a problem that no previous design for a tilting four-

wheel vehicle has solved: the transfer of power from the differential to the wheels. In my design the differential

does not tilt, and consequently the system of axles and u-joints is the same as a typical front wheel drive car (a

proven technology) avoiding the considerable expense and inefficiency of the technology involved in current

tilting four-wheel power train designs (extreme u-joint angles, long axle slip joints or multiple chain or shaft

drives).

Designing and building this entire vehicle in one year is probably not feasible, and thus this year‘s project will

involve choosing, designing, and building a subset of the vehicle is an option.

Project Duration:

2 semesters


Dynamics, vehicle dynamics machine and structural design, electric circuits, fluids, manufacturing



4 ME students

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